Left side door install day. I laid out the table for working on the door along with all the associated parts to assemble the exterior door handle, lock, window motor, inside door handle & locking device, the several rails and special clips (several were broken) and the door hinge pin system.
Bruce was coming over to help (Thank goodness, there is no way to do this install alone) and while I was waiting for him I put the car on the lift and installed two rubber grommets' in the chassis holes where the heater and choke cables go thru. I had forgotten to install those and didn't want to forget again. Tough location to reach after the car is assembled, so remember to do this when the chassis of off the body.
Bruce arrived in his Elan S2 (Great sports car driving day) and we set about installing everything in the door. Of course it all take hours...... The exterior door handle needed fettling as there was new fiberglass installed where the door handle had pulled out. And then we had to install the motor (that was easy) and the control rods that operate everything (that was hard). I had bought new clips for the control rods and they were such a tight fit you couldn't snap them in place with your fingers. Had to use pliers.........in a space that isn't meant for a pair of pliers. And then the dock locking mechanism was being difficult. Bruce kept at it while I moved to the installed door to install the new clips. We were both doing the same thing on two different doors grumbling “no wonder they could only build 5 cars a day at the Lotus factory”.
Larry stopped by to see what progress had been made since he helped with the rear window installation. He was very surprised how much had been done and thought I would only be a couple of days from finishing. Yes, I thought so too, but no way I would make it to New Hope on Sunday. He agreed.
Bruce and I went to lunch and stopped by the local Ace hardware store (they have a great bolt department) to pick up some stainless steel washers. I thought the bottom hinge of the door could use an extra washer (three instead of two) but didn't had the right size in stock at home.
Back at my garage we prepped for the door hinge install. Taped the opening area of the door, test fit the pin in the bobbins, greased the inside of the bobbins, the SS pin, the SS washers (to hold them in place) and the inside of the SS door receivers. As I had done this all before on the right door last week I figured this would be a breeze. I would be wrong.
I wont go into all the gory details but ..........Two and one half hours later we stood back to admire our work and remove the masking tape from the body. Yup, looks great but can't close the door all the way because the new rubber door molding forces the door to be too proud.
I was running very late for a planned dinner at a local restaurant and had to say thanks and goodbye to Bruce quickly. I have to tell you, got to appreciate good friends who come to help get your Lotus back together! Really appreciate it Bruce!
While driving to the restaurant my wife say's "you and Bruce where in the garage for almost 10 hours today and all you got done was one door?" Yes dear. "I just don't understand how you guys are so passionate about these cars". Yup, neither do I.......... I just need a drink.
